System design, proposal and programming method and apparatus

ABSTRACT

A technique is provided or integrating system design, sales, and manufacturing functions. Systems including networked and programmable electrical components, such as motor control centers, and other electrical power control arrangements are designed, and a database is created for the design, including component and system designation data. The database may further include configuration information, settings, and so forth. The database is used as a tool in establishing a sales solicitation proposal from which sales of the system are offered. The same database is then used to program the various components of the system, such as through a temporary network link or via a permanent data network once the system is assembled.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of electricalcontrol and monitoring systems, and more particularly to a system andmethod that integrates functions of design, sales and marketing,manufacturing, and programming of system components.

In the field of electrical controlling monitoring systems, varioustechniques are known and are currently employed for completing initialsystem designs, and manufacturing systems based on the designs followingsales. Due to the often separate nature of the design, sales, andmanufacturing operations, however, existing systems typically treatthese phases of the product cycle quite distinctly. Conventionally,engineered systems are designed by engineers and technicians for regularproduct offerings or for client or application-specific implementation.The designs might include component and system specifications, drawings,and so forth. Components may be selected from manufacturer's literatureor catalogues in accordance with the specifications. Based upon a systemdesign, a sales or marketing proposal would be provided for evaluationand use as a basis for placing an order for the system.

Following receipt of an order, a manufacturer or systems integratorwould typically revert to the initial system design for ordering partsand assembling the parts into the final system. Where programmablecomponents were included in the system, specialized programmers ortechnicians pre-program certain components manually, and visit theinstallation site to carry out final programming and trouble shootingneeded to bring the system into complete compliance and functionality.Such manual programming is, however, quite costly and can lead to errorsthrough data input, manual and machine copy errors, and so forth.Moreover, locating, identifying, and correcting such errors are alsovery time consuming operations.

Although electrical systems have become increasingly sophisticated, theprocedures used for designing, selling, manufacturing and programmingsuch systems has evolved very little. Modern industrial control andmonitoring systems, for example, may include a large number ofprogrammable devices which function interactively to carry out specifiedautomation procedures. However, the approach to designing, selling andinstalling the systems still requires that programmers or specializedsoftware be employed to implement the system design in compliance withthe initial layout, with no appreciable link between the initial designprocess used for generating a sales solicitation and the manufacturingand programming operations.

There is a need, therefore, for an improved technique which may beemployed to design, sell, manufacture, and program systems, particularlyin the area of industrial automation. There is a particular need for atechnique which will not only facilitate the design, sales solicitation,and manufacturing operations, but which will provide greater uniformityand consistency between the initial design and the final implementation,reducing or avoiding time consuming operations and errors which mayoccur in conventional processes.

SUMMARY OF THE INVENTION

The present invention provides a novel technique for integrating design,sales, manufacturing, and programming functions designed to respond tothese needs. The technique may be employed with a wide range of systems,but is particularly well suited to industrial automation systems wherevarious programmable components are integrated for cooperativefunctions. In accordance with the technique, the design of the systeminitiates a database which serves as the basis for componentspecification, network designations, and so forth. The database is usedto generate the initial sales proposal, and may be modified inaccordance with modifications in the proposal or specification.

Based upon a received order, the database information is then used as abasis for manufacturing operations. Specifically, the database may servefor ordering parts, assembling the parts, wiring the parts, and soforth. Finally, data stored in the database and available throughout theprocedure, may be downloaded to specific components, such as to identifythe components, their functions in the system, system designations,locations of components in the system, network node points, and soforth. The present technique thus provides an enhanced integratedapproach to system design, sales, and implementation.

In an exemplary embodiment, the technique may be employed forspecification of components in networked industrial automation systems,such as motor control centers. In a motor control center application,software used to design the system and specify components, such as motorcontrollers, variable speed motor drives, relays, switch gear, and thelike, initiates the database which is used throughout the integratedprocedure. Pricing information, delivery information, and the like maybe accessed based upon the specifications to generate a sales ormarketing proposal. Once a solicited order is received, parts may beordered specifically for the motor control center from the database, andthe components are assembled into subunits. Either at the sub-unitlevel, or following final or partial assembly of the system, entriesfrom the database are downloaded into programmable components to aid inthe system implementation and programming, such as to identify thedevice node, locations in a motor control center enclosure, and soforth. The data downloaded into the component is therefore consistentwith the initial system design, the sales proposal, and any changes madein these. The data may serve as a basis for later accessing, polling,monitoring or controlling the various components.

The technique effectively creates a “self organizing” softwareapplication and process in that facilitates customized design of systemsof components, without the need for conventional customized design forspecific systems. The technique is thus useful for a wide variety ofsystem types, including systems for controlling automation equipment. Itmay be applied to broad groupings of equipment both in the automationenvironment (e.g. in motor control centers) and in other environments.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other advantages of the invention will become apparentupon reading the following detailed description and upon reference tothe drawings in which:

FIG. 1 is a diagrammatical representation of an electrical control andmonitoring system including networked programmable components andmonitoring stations, remote resources, and additional network componentsin accordance with aspects of the present technique;

FIG. 2 is a diagrammatical representation of certain functionalcircuitry within a networked component in a system such as that shown inFIG. 1;

FIG. 3 is a diagrammatical representation of components of a translatormodule for use with non-networkable or non-programmable, components in asystem such as that shown in FIG. 1;

FIG. 4 is a diagrammatical representation of functional elementsincluded in a monitoring station designed to access data from componentsin a system such as that shown in FIG. 1 and to display data relating tocomponent status and operating parameters;

FIG. 5 is a diagrammatical representation of certain dedicated memoryobjects included in programmable components of the system of FIG. 1 forstoring portions of a database distributed among the components andincluding data for designating the system, the components, and so forth;

FIG. 6 is a diagrammatical representation of functional components in anintegrated design, sales, and programming arrangement for implementing adistributed database in a system such as that illustrated in FIG. 1;

FIG. 7 is a diagram illustrating links between user viewable pages orrepresentations in a monitoring station linked to a control andmonitoring system;

FIG. 8 is an elevational or physical layout view of a system of the typeshown in FIG. 1 in an exemplary embodiment of software running on amonitoring station;

FIG. 9 is a device monitoring view accessible from the elevational viewof FIG. 8 for certain of the programmable components;

FIG. 10 is a view of one of the user viewable representations, such asthat of FIG. 9, and illustrating the real time selection of a desiredlanguage for textual labels stored and accessible from the systemdatabase;

FIG. 11 is a spreadsheet view for component operating parameters andsettings accessible from the physical view of FIG. 8;

FIG. 12 is a view of event logs viewable on a monitoring station andillustrating links to drawings, reports, manuals and spare parts listsin an integrated documentation system;

FIG. 13 is a view of support materials, such as manuals accessible fromthe menu illustrated in FIG. 12; and

FIG. 14 is a flow chart illustrating exemplary logic in the design,assembly, programming, and operational phases of the system illustratedin the foregoing figures.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Turning now to the drawings, and referring first to FIG. 1, a controland monitoring system 10 is illustrated as including a componentassembly 12, and a network 14 for transmitting data to and fromcomponents of the assembly. While the component assembly 12 may takemany forms, and include devices for accomplishing many different andvaried purposes, in a preferred implementation, the component assemblyincludes electrical control and monitoring equipment for regulatingapplication of electrical power to loads. In particular, the componentsmay include motor starters, motor controllers, variable frequencydrives, relays, protective devices such as circuit breakers,programmable logic controllers, and so forth. In the industrialautomation field, such component assemblies are commonly referred to asmotor control centers (MCC's).

In addition to the component assembly and network, system 10 includes asystem controller 16 and a monitoring station 18. System controller 16may, in fact, be defined by various devices both within and external tothe component assembly, and may comprise computer systems connected tothe component assembly via network 14. Where included in the system,system controller 16 may store programs, routines, control logic, andthe like for regulating operation of the components of the system.Monitoring station 18, described in greater detail below, may be localto or separate from system controller 16. The monitoring station permitsoperational status and parameters to be monitored in real time, andaffords programming of certain of the components of assembly 12. Itshould be noted that while a single assembly 12 is illustrated in thefigures and described herein, the component assembly 12 may, in fact,include a range of assemblies, each located near one another or remotefrom one another in a particular application, interconnected withcontroller 16 and monitoring station 18 via network 14.

Network 14 may also permit data exchange with additional monitoring andcontrol stations. For example, in the illustrated embodiment, a fieldengineer laptop 20 may be coupled to network 14 to producerepresentations of the system, monitor parameters sensed or controlledby the system, program components of the system, and so forth.Similarly, one or more gateways 22 may be provided which link network 14to other networks 24. Such networks may use a similar or completelydifferent protocol from that of network 14. The other networks 24 mayinclude various remote devices, as indicated generally by referencenumeral 26, which permit remote monitoring and control of components ofthe system. One or more of the control or monitoring stations in thesystem may be adapted to be linked to outside elements by wide areanetworks, as represented generally at reference numeral 28, includingthe Internet. Thus, monitoring station 18 may access remote resourcesand monitoring equipment 30 via wide area network 28, as described morefully below.

It should be noted that, while reference is made herein to a wide areanetwork 28, other network strategies may be implemented in the system,including virtual private networks, dedicated communications links, andso forth. While any suitable network 14 may be used in the system, in apresent embodiment, an industry standard network is employed, referredto commonly under the name DeviceNet. Such networks permit the exchangeof data in accordance with a predefined protocol, and may provide powerfor operation of networked elements.

Component assembly 12 comprises a range of components, designatedgenerally by reference numeral 32. The components are situated in anenclosure set 34 which may include a single or a plurality of separateenclosures. The enclosure set 34, in the illustrated embodiment,includes sections 36 in which subunits or sub-assemblies of thecomponent assembly are situated. In practice, the enclosure set may bedefined by a large enclosure in which individual panel-mounted subunitsare positioned in bays 38. Between each of the sections or bays,wireways 40 serve to channel wiring, including trunk and drop cablingfor network 14. As will be appreciated by those skilled in the art, oneor more power busses 42 serve to convey electrical power to theenclosure, which is routed to each of the components to regulate theapplication of the power to downstream loads, such as electric motors,valves, actuators, and so forth.

Components 32 generally include both an operative device, designatedgenerally by the numeral 44, along with network interface circuitry 46,and load-line interface circuitry 48. While reference is made herein,generically, to a component device 44, it should be noted that in anindustrial automation context, such devices may include any or all ofthe power regulation devices mentioned above, as well as others. Ingeneral, the devices may serve to regulate any useful industrial processor load, and may be configured to function in cooperation with oneanother, such as to protect the other components from overcurrentconditions, loss of phase, ground fault, or any other abnormal orunwanted condition. In normal operation, the devices function inaccordance with a predetermined routine or program, either stored withinthe devices themselves, in memory of a programmable logic controller, orin memory of a system controller 16. Moreover, operation of the devicesmay be regulated in accordance with parameters sensed by the componentsthemselves, or by system sensors. Finally, operation of the devices maybe regulated by operator-induced command inputs, including inputs madevia a computer interface, push buttons, switches, or in any othersuitable manner.

The components may be configured for direct connection to the datanetwork 14, or may require connection to the network a translator 50. Inthe illustrated embodiment to FIG. 1, translator 50 serves tocommunicate data to and from a downstream device 52 which is notequipped for directly receiving and transmitting data via the network.As noted below, the components preferably include dedicated memoryobjects which facilitate certain of the monitoring and control functionsof the system. Where a downstream device 52 does not include suchobjects, or is not equipped for data communications in accordance withthe network protocol, a translator 50 may, instead, include thenecessary memory objects, and serve to take on the identity of thedownstream object from the point of view of the data network,translating data from the device in accordance with a second protocol asdefined by the device, such as a CAN protocol known as SCANport in apresent embodiment. In such cases, the translator 50 includes a deviceinterface 54 which communicates with the downstream device 52 inaccordance with the second protocol. Translator 50 may further includeinput/output interface circuitry 54 for transmitting and receivinginformation with other devices of the system. While not illustrated inFIG. 1, certain of the components 32 may include similar input andoutput interface circuitry, permitting them to similarly exchangeinformation with external devices of the system.

When positioned in the enclosure set 34, the components, devices,translators, and other elements of the system, may be represented ashaving specific locations or coordinates 58 and 60. In the illustratedembodiment, coordinate 58 represents a horizontal location of thecomponents from a left-hand side of the enclosure set. Coordinate 60, onthe other hand, represents the location of the components from a topside of the enclosure set. As noted below in greater detail, memoryobjects of each component or translator may store data representative ofthese coordinates to facilitate their location in the system, as well asto enhance certain of the monitoring and display functions of thesystem. In addition to coordinates 58 and 60, the components may includephysical extent designations, such as size or space factors, designatedgenerally by reference numeral 62, corresponding to the relative extentof a component or a sub-assembly within the enclosure set. As will beappreciated by those skilled in the art, coordinates 58 and 60, andfactors 62 may permit the components to be accurately located anddepicted in the system as described below.

Monitoring station 18 includes a computer console 64 in which varioustypes of memory supports 66 may be employed, such as magnetic or opticalmemory devices (e.g., CD ROM's). The computer console 64 is adapted tocooperate with peripheral devices, such as conventional computer monitor68, and input devices such as a keyboard 70 and mouse 72. Moreover, theconsole 64 may cooperate with additional peripheral devices, such as aprinter 74 for producing hard-copy reports.

Certain of the functional circuitry contained within each component 32is illustrated in FIG. 2. As noted above, each component 32 will includea control or monitoring device 44, such as a conventional device forregulating application of electrical power to a load. The devices, whenadapted to regulate power in this way, may include single or multi-phasearrangements, and may operate on mechanical, electro-mechanical or solidstate principles. A network interface circuit 46 permits the exchange ofdata between the component and other devices coupled to network 14 (seeFIG. 1). Network interface 46 will be adapted to encode data inaccordance with the protocol of the network, such as the DeviceNetprotocol mentioned above. The components further include a processor 76which communicates with the control and monitoring device 44 and thenetwork interface 46 to control operation of the component, and toprovide access to and exchange of data representative of states,parameter levels, and so forth, controlled by or monitored by device 44.Processor 76 is associated with a memory circuit 78, which willtypically include a solid state, resident, non-volatile memory which isembedded and maintained on-board the component 32.

As discussed more fully below, memory circuit 78 includes one or morededicated objects 80 which are allocated for specific datarepresentative of the system, the component, the component function, thecomponent location, and so forth. Thus, memory objects 80 includesectors or blocks 82, typically each comprising a plurality of bits, forstoring code representative of the designated data. Processor 76 mayalso receive inputs from sensors 84 which are external to device 44.Both device 44 and sensors 84 may serve to sense any suitableoperational parameters, such as current, voltage, frequency, speeds,temperatures, and so forth.

Similar functional circuitry is included within each translator 50, asillustrated generally in FIG. 3. As with components 32 (see FIG. 1),translators 50 include a processor 76 which cooperates with a networkinterface circuit 46 to exchange data between the translator and otherelements of the system. Processor 76 also operates in conjunction with adevice interface 54 which is adapted to exchange data between thetranslator and a control or monitoring device 52, which is either notprogrammable as desired in the network or networkable in accordance withthe protocol of network 14 (see FIG. 1). Moreover, processor 76 islinked to a memory circuit 78 which stores routines carried out by theprocessor, as well as dedicated memory objects 80 as described above.Finally, translators 50 may include one or more input/output nodes orterminals 86 for exchanging data with other elements or devices (notshown) and the network. By way of example, input/output nodes 86 maypermit linking of the network to various sensors, actuators, and thelike. Where desired, as in a present embodiment, translators mayaccommodate inputs only, or neither inputs nor outputs. Moreover, in apresently preferred embodiment, DIP switches (not shown), allow forselection of one of multiple operating voltages for the translator 50,including 24 VDC, 115 VAC and 230 VAC.

Monitoring station 18 may include, as a software platform, any suitableprocessor or computer workstation. As illustrated in FIG. 4, thecomputer 64 includes a processor 88, such as a Pentium III processoravailable from Intel. Processor 88 carries out instructions and managescollection and display of operational parameters in the form of userviewable representations as described below. The processor thuscommunicates with a network interface 46 in a manner similar to theinterfaces included within each component, linking the monitoringstation to network 14 (see FIG. 1). Moreover, processor 88 communicateswith its associated peripheral devices via a peripheral interface 90. Awide area network interface 92 is included within the monitoringstation, and may include any suitable network circuitry, including adial-up modem, a cable modem, a wireless modem or other network circuit.A memory circuit 94 is provided within computer 64, and may include arange of memory devices, such as solid state memory chips, magnetic diskdrives, hard drives, and CD ROM drives.

Referring to FIG. 5, a database 96 is stored within computer 64, and, inpractice, may be included within one or more of the memory circuits 94.Due to the nature of the database and its functions in the system,however, separate reference is made herein to the database and theinformation contained therein. As noted below, processor 88 relies upondatabase 96 for many of the control or monitoring functions, includingcommunication with the system components, programming or reprogrammingof the system components, generation of user viewable representations ofthe system, and so forth.

Database 96 serves as the foundation for programming of memory objectswithin the components and translators of the system. In a presentembodiment, the database is established during system design, but may bemodified subsequently depending upon system requirements and systemredesigns. The database includes entries 98 designating the system, thecomponents in the system, physical and configuration parameters of thecomponents, textual labels for user viewable representations, systemsettings, events, and so forth as described in greater detail below. Thedatabase also serves as the source for data stored within the memoryobjects of each component and translator.

As illustrated in FIG. 5, at least two such objects are preferablyincluded within the components and translators. A first object 100 isconfigured at the time of manufacturing of the component, or subsequentto manufacturing and during installation of the component in the finalsystem. Such memory objects will preferably include blocks 82 allocatedby specific bits for encoding data 104 representative of the componentidentification. As illustrated in FIG. 5, the block data 104 of object100 preferably includes code identifying the product itself, therevision number of the product, if any, a manufacturer of the product, anetwork node designation, and a data exchange baud rate. Again, the codeneeded to populate each of the allocated blocks 82 may be stored withindatabase 96 and may be altered as needed. In a present embodiment, datadownloaded into the components is derived from database 96 byreformatting the data to conform to the allocated blocks 82.

A second memory object 102 stores additional data derived from database96. Such data remains resident within each component or translatorfollowing system assembly. The block data 104 of memory object 102includes code which identifies or designates the system, the components,and physical location or configuration information for the components.Moreover, object 102 preferably includes allocated memory forconfiguration of input or output nodes coupled to the network via thecomponent. In the illustrated embodiment, object 102 includes coderepresentative of a system identification, a system extent or size, theidentification of a section within which the component is located, asize or space factor, a width factor, a device type, a number of inputpoints within the node, a device type for each of the input points, ifany, a number of output points in the node, and designations for devicetypes of any outputs, if any. It should be noted that certain componentsor translators may accommodate inputs only, outputs only, or neitherinputs nor outputs.

In general terms, the system identification code and system extent orsize code is representative of the system in which the components arelocated. Because many applications may include several such systems,this data aids in monitoring and viewing component information byindividual system. The section identifications, space factor and widthinformation, generally corresponding to the coordinates 58 and 60, andto the size factor 62 discussed above with reference to FIG. 1, aid inlocating the components within the system for physical layoutrepresentations as described below. The device type information mayinclude data representative of the physical or wiring configuration ofthe components, such as code representative of full voltage,non-reversing motor starter, three-phase overload relay, and so forth,by way of example. Finally, the input and output configuration fieldsare provided in sets, in accordance with the number of inputs andoutputs interfaced at the node.

As noted above, data which populates each dedicated memory object of thecomponents or translators is preferably stored in the objects duringinitial configuration, but may be modified subsequent thereto. Inaccordance with certain aspects of the present technique, an integrateddesign, sales, and manufacturing system permits the database 96 to beused for a number of purposes throughout the life of the system, fromits initial design to its final implementation. FIG. 6 representsfunctional blocks in a configuration system 106 designed for thispurpose.

As illustrated in FIG. 6, individual components 32 are designed into thesystem, and are intended for location within specific sections 36 andbays 38 of the enclosure set. The sections and bays may includetranslators 50 and their associated downstream devices 52, particularlywhere the downstream devices are not designed to interface with thesystem data network, or where the downstream devices do not include thededicated memory objects described above. The configuration system 106includes a design module 108 which may comprise software and hardwarefor developing an initial system design. The design module 108, forexample, will typically include one or more computer workstations onwhich software is provided for producing system layouts andconfiguration information. The design module accesses additionalinformation, such as pricing information, availability information,configuration data, serial numbers, model numbers, and the like, forgeneration of database 96. Based upon database 96, a sales solicitationmodule 110 uses the same database data entries for generation of a salessolicitation proposal 112. In general, proposal 112 will be a textualdocument (including, where desired, diagrams, schematics and so forth),which sets forth specifications for the components defined in database96, as well as their implementation within the system. The salesproposal 112 may also include information relating to delivery times,programming, pricing, and so forth.

In accordance with the present technique, the database established inaccordance with the design set forth by the design module 108, and usedby the sales solicitation module 110 for generating proposal 112 thenserves to configure the actual objects contained within the componentsand translators of the system. A configuration tool 114, referred to inthe system as a “configurator,” serves to extract data from the databaseneeded to populate each dedicated memory object of the components. Assummarized below, the configurator may be linked to the components priorto their assembly in the system, or during their mounting within theindividual sections or bays which are subsequently placed within theenclosure set. Thus, the configurator may be linked to the componentsvia a temporary network link to address the memory locations of theobjects, and to download the corresponding entries from database 96 intothe objects. Alternatively, the configurator may be linked to thecomponents following partial or final assembly of the system, such asthrough the data network 14 discussed above.

The processor of monitoring station 18 (see FIG. 1) executes softwarefor cyclically polling the components of the system via network 14. Thesoftware also serves as the basis for generating a series of userviewable representations or screens depicting the system, componentconfiguration information, monitored parameter levels, and so forth.FIG. 7 represents the association of various views available to a userin accordance with a present embodiment of the routine. The routineillustrated in FIG. 7 includes a main menu 116 from which a variety ofrepresentations may be accessed. For example, from main menu 116 a usermay connect directly to the line-up or component assembly 12 illustratedin FIG. 1, as indicated at reference numeral 118 in FIG. 7. From themain menu or from the lineup connection link, a physical view may beselected as indicated at reference numeral 120. As described more fullybelow, the physical view provides a dimensionally and dispositionallyapproximate layout the system and components reconstructed from dataacquired from the various components and translators. A spreadsheet view122 may be selected from either the main menu or the physical view 120.The spreadsheet view, as described below, includes data entries, againdrawn from database 96 (see FIG. 6), representative of the components,their identifications, their settings, their locations, and so forth. Amonitor view 124 is provided for each component or device. The monitorview, also described below, provides for descriptions of the components,and may include images of the components, as well as graphical displaysof current and historical parameter levels.

In addition to the menus and views summarized above, the softwareoperative on the monitoring station also preferably affords easy accessto a variety of support documentation, from a node point in FIG. 7represented by reference numeral 126. The support documentation mayinclude electronic files stored at the monitoring station, in residentmemory of the monitoring station or in any memory medium (e.g., CD ROM)usable at the monitoring station, but may also include data files storedremote from monitoring station, such as at remote resources as discussedabove with FIG. 1. In a present embodiment, a wide range of supportdocumentation may be accessed directly from the user viewablerepresentations. For example, the data files may include system orcomponent drawings 128, manuals 130, reports 132, and parts lists orbreakdowns 134. The support documentation is preferably referenced atthe creation of the system, such as through database 96 as discussedabove. Thereafter, the documentation is stored for ready access viasoftware links through the views accessible on the monitoring station.Thus, the data files for the support documentation may be referenceddirectly at the monitoring station without interrupting the monitoringor control functions carried out by the processor.

It should be noted that the software summarized above with reference toFIG. 7 may include additional or other screens, links, representations,and functionalities. Moreover, the software may be designed to operatein conjunction with additional software for other purposes, and may bemulti-tasked with other software, such as browsers, spreadsheetapplications, text editing applications, and so forth.

FIGS. 8-13 illustrate certain user viewable representations accessibleon the monitoring station in accordance with the aspects of a presentembodiment. As noted above, an extremely useful feature of the presentsystem is the ability to build, in real time, an approximately accuratephysical layout view or representation of the system and componentsbased upon information stored within the dedicated memory objects of thecomponents themselves. FIG. 8 represents a user viewable representation136 which includes a page or screen 138 viewable on the monitor 68 (seeFIG. 1) of the monitoring station. In the illustrated embodiment, thescreen includes navigational bars or tools 140, such as virtual buttonswhich may be selected or actuated by an operator via an input devicesuch as a conventional mouse. A scroll bar 142 is provided for movingbetween sections or portions of the system illustrated in therepresentation. A system label 144 designates which system is beingviewed, and is based upon the system designation data stored within thememory objects of the components.

In the physical representation of FIG. 8, a depiction 146 is provided ofthe physical layout of the component assembly. In the illustratedembodiment, this depiction is approximately accurate in terms of therelative disposition of the components in the system, their coordinatesin the system, and their relative sizes. The relative sizes andlocations of the component representations in depiction 146 are basedupon data stored within the memory objects of the components. Inparticular, as noted above, the memory objects of each component ortranslator include data indicative of the component locations, theirsizes, and so forth. Based upon this data, the physical depiction 146can be reconstructed, even without specific information orpreprogramming of the depiction within the monitoring station. Moreover,each component representation in the depiction 146 preferably includes astatus indicator 148 for identifying a current status of the respectivecomponent. A legend 150 provides the user with a translation of themeaning of each status indicator. Component textual labels 152 areprovided for each component representation. The component textual labelsare also based upon component data acquired from each component. Again,the component data is stored within the memory objects described above,and is used as a reference for extracting the component textual labelsfrom the database.

It will be noted that the representations described herein, includingthe representation of FIG. 8, include a series of textual labels, suchas for the components, their designations, legends, viewidentifications, and so forth. All such textual labels, designatedgenerally by the reference numeral 154, are preferably stored as entrieswithin database 96 (see FIG. 6) as described more fully below. Thus, inaddition to the other functions of the monitoring station, the variousrepresentations available on the monitoring station may be viewed in oneof a plurality of selectable languages by reference to specific textuallabels stored within the database. Moreover, the representations includea series of links 156 which may be accessed by the user in various ways.For example, in a present embodiment, links may be accessed vianavigational tools 140, or by selection of specific components in thedepiction 146. In the embodiment illustrated in FIG. 8, such links mayinclude monitoring representations, component data editing tools, systemsection editing tools, and documentation. As noted above, several typesof documentation or support information may be accessed, such as viaadditional document links 158.

FIG. 9 represents a monitor view for the components of the systemaccessible from the physical representation of FIG. 8. The monitorrepresentation 160 includes series of features which inform the user ofparameter status, component status, component settings, and so forth. Inthe illustrated embodiment, the monitor representation includes acomponent designation or label 162, derived from information storedwithin the memory object of a desired component selectable by the user.Based upon the component identification, the monitor representation 160presents a textual component description 164 which includes basicinformation on the component and its operation. An image 166 of thecomponent is provided to aid in visual recognition of the component inthe event of needed servicing.

The monitor representation 160 of FIG. 9 also includes a range ofparameter representations, indicating current levels of operatingparameters, as indicated at reference numeral 168, and historicallevels, as indicated at reference numeral 170. The specific parametersrepresented in the screen are preferably selected based upon thecomponent identification, its operation and function in the system, anddefaults stored for the component. In the illustrated embodiment, thecurrent level indications include a series of virtual meters 172 whichindicate levels of the default parameters, as indicated at referencenumeral 174, or of operator selected parameters, as indicated atreference numeral 176. In the illustrated embodiment, the defaultparameters include output frequency, while a user selected parameter isbus voltage. Because many of the components of the system are capable ofmonitoring and controlling a wide range of parameters, key defaultparameters are selected in advance, depending upon the configuration andfunction of the respective components, while the operator may overridethe defaults and select the other parameters from pull down menus, orsimilar tools.

In addition to the indication of current parameter levels, the monitorrepresentation 160 includes displays of historical parameter levels. Thehistorical displays may take any convenient form, and in a presentembodiment imitate conventional strip chart output as indicated atreference numeral 178 in FIG. 9. Again, the particular parameters tracedin the strip chart output, or any other suitable historicalpresentation, may include default parameters for the particularcomponent, or operator-selected parameters.

The monitor representation 160 may further include textualrepresentations of various settings, configurations, and so forth, forthe particular component. In the embodiment illustrated in FIG. 9, thecomponent includes inputs and outputs, with appropriate interfacingcircuitry within the component. The configurations of the inputs andoutputs are provided in the memory objects as discussed above. Themonitoring station accesses this data and provides information on theinputs and outputs as indicated at reference numeral 180. Finally, themonitor representation illustrated in FIG. 9 includes textual ornumerical indications of particular parameter levels, settings, times,frequencies, or any other suitable set points or level indications. Asindicated by reference numeral 182, these may include both text andparameter levels, with appropriate textual labels for each.

The various views created and displayed in accordance with the presenttechnique include a variety of textual descriptions and labels which maybe displayed in various languages as desired by the user. In a presentembodiment, the multilingual aspect of the representations isfacilitated by the inclusion of language entries for each label, storedwithin database 96 (see FIG. 6). The user may select a languageselection tool from a menu, such as a preference menu of the typeillustrated in FIG. 10. Within the menu, a language tab allows the userto select the desired language, and the various language selections maybe translated, themselves, into other languages for selection.

In the embodiment illustrated in FIG. 10, a user selects a desiredlanguage, such as Spanish, from a dropdown menu 184. The languages aredisplayed within the menu, and are selected via an input device, such asa conventional computer mouse. The list of languages, identified byreference numeral 186 in FIG. 10, allows for selection of any desiredlanguage for which textual translations are stored within database 96.Once a selection is made, the program automatically begins to draw alltextual labels, descriptions, headings, and so forth from theappropriate entries 188 of the database 96.

The provision of the multilingual entries translated into the availablelanguages in database 96 offers several distinct advantages. Forexample, the user may switch languages as desired during operation ofthe system, and without interrupting other functions of the system, suchas real time monitoring and control. Moreover, the languages may beavailable for building real time views, including the physical view andthe monitoring views at various locations accessible via a networkinterface as described above. A given system may thus be servicedremotely, such as by network connection to a different country orlocation. Furthermore, the provision of languages in translation asentries within the database permits the software to be provided in asingle version and easily upgraded by simply allowing for access to asubsequent series of entries in the database, with corresponding optionsin the language menu.

In addition to the foregoing views, the present technique provides aspreadsheet-type representation or page which may be organized for eachcomponent, or for the entire system as illustrated in FIG. 11. In therepresentation of FIG. 11, the spreadsheet view 190 is referenced bysystem identification as indicated at reference numeral 144 based uponthe information stored within the memory objects of the components ofthe system. Within the spreadsheet view, textual entries are providedincluding component designation data 192, also accessed from theindividual memory objects of the components. In the embodimentillustrated in FIG. 11, the component designation data includes a devicetype, a node address, a vertical section and a unit location, the latterto parameters providing coordinate information for the identifiedcomponent. Additional component designation data 194 may be viewable inthe screen, including, in the illustrated embodiment, information storedwithin the components and indicative of a hardware, software or wiringconfiguration. In the illustrated embodiment the unit type, for example,may include textual information referenced from the database andcorresponding to function data stored within the memory objects. By wayof example, the text “FVNR” may be provided to represent a componentwhich is configured as a full voltage, non-reversing motor starter.Additional such configuration data may include component rating, catalognumbers, and so forth. To facilitate manipulation of the data, and topermit user-selectable displays, a menu 196 may be provided in which auser may select to display or not to display specific system orcomponent data by column.

Because the system provided herein is designed to cyclically poll thecomponents for their state and specific operational parameters, eventsfor the individual components or for the entire system may be logged.FIG. 12 illustrates an exemplary event log 200 stored for the systemidentified in the window 144 based upon the memory object data stored inthe components. The event log may include a range of event types, suchas specific faults or abnormal operating conditions, normal operatingconditions or events, changes in component settings, and so forth. Inthe embodiment illustrated in FIG. 12, the event log includes componentdesignation data 202, referencing each component by the device serialnumber, again based upon the information drawn from the device memoryobjects. An event time 204 is provided for each log event. Additionalevent data, as indicated generally by reference numeral 206 provides anindication of the type of event which occurred. Additional data may bestored within the system and accessed via the event log, such as toprovide even further descriptive information on the nature of the logevents.

As noted above, the present system permits the real time monitoring,physical view construction, event logging, and so forth, with linksdirectly to support documentation. FIG. 13 illustrates a series ofwindows accessed from the physical view of FIG. 8. As noted above,support documentation may be accessed in the system in any suitablemanner, such as via dropdown menus which are accessible from theindividual component representations in the physical view. Moreover,such selections may be available through virtual buttons or similar useractuatable features 140 in the various views. In the present embodiment,as shown in FIG. 13, a menu is displayed for the user upon selection ofthe documentation item from a menu, and specific additional menus may beprovided for drawings, reports, manuals, and spare parts. The links tothe support documentation are preferably based upon data stored withinthe various memory objects, particularly the device designation data.The document selection menu 208 is thus displayed, such as for manualsin the illustrated embodiment. Component designation data 210 appearsfor selection by the user. In the embodiment illustrated in FIG. 13, thecomponent designation data includes an identification of the componentlocation or coordinates, and the component configuration or function.Support documentation which is available for the component is indicatedin an additional window 212. By selecting the links from this window, auser may access manuals for the specific components. As indicated above,the support documentation, including the drawings, reports, manuals, orspare parts lists are preferably stored in a memory medium useabledirectly in the monitoring station, such as a CD ROM disk or disk set,or in database 96. Certain of the documentation may be stored in systemsor workstations external to the monitoring system, however, including inlocations remote from the monitoring system and accessible via the datanetwork, local area networks, wide area networks, and so forth. Uponselection of a specific document, the document is displayed, with thesoftware calling the appropriate application for display of thedocument, including text editing programs, drawing programs, imagedisplay programs, and so forth.

As noted above, the present technique permits an integrated system fordesigning, building, and utilizing electrical components in aprogrammable networked system, such as a motor control center. Thetechnique includes, in the preferred embodiment, a database which isestablished during the design phase, and which is used as the basis forprogramming or configuring memory objects stored within the networkedcomponents and devices. FIG. 14 summarizes exemplary steps employedthroughout this process.

As illustrated in FIG. 14, the process, designated generally by thereference numeral 214, includes several phases, including a design andsales phase 216, a manufacturing and configuration phase 218, and autilization and monitoring phase 220. The first phase 216 begins withthe design of the system as summarized at block 222. As noted above,system design may be based upon any suitable software application usedfor integrating the components into a cooperative system, and forgenerating any specifications required for verifying the operability ofthe design. At step 224, the physical and component configuration datais stored within a database. The database 96 is stored at this stage inthe logic for use in soliciting sales of the system, and in thesubsequent programming. As noted above, the database will serve as aplatform for configuring the components, and will effectively bedistributed among the components, at least in part, during the componentconfiguration. At step 226 the design is used to generate sales proposal112, which is also based upon the database. Step 226 may includeincorporation of additional data external to the database, such as priceinformation, deliver program (in general any suitable type ofavailability information), and so forth, for each component of thesystem. Step 226 produces a sales solicitation proposal 112, or similardocument which may be used to establish the system specification, terms,and so forth.

Phase 218 in the process includes assembly of the components andsubunits of the system, as indicated at step 230. The assembly mayproceed by subunit or subassembly, such as in sections or “buckets” incertain types of system. Each subunit may therefore include one or morecomponents which are mounted within the subunit and interconnected withwiring to permit their later incorporation into the system. At step 232the components of each subunit are configured from database 96, such asby downloading database entries into the memory objects embedded withineach component. At step 234 the components and subunits are assembledand installed in the system. In many applications, step 234 will includemounting of the actual components in system enclosure sets, along withany support connections and monitoring systems at a customer location.At step 236 the components may be further configured, such as via thedata network described above. It should be noted that componentconfiguration may occur at either step 232 or at step 236, or at bothsteps, depending upon the desired configuration data and the manner inwhich it is downloaded into the components. Thus, the configuration ofthe components may occur prior to assembly, during assembly, such asfollowing partial assembly and subunits, or following system finalassembly.

Phase 220, involving actual use of the system for monitoring and controlpurposes, may begin with step 236 in which the components are configuredvia the data network. Step 236 is also shown as at least partiallyincluded in phase 220 because, as summarized above, the memory objectsmay be designed for reprogramming or reconfiguring during use of thesystem. Such reconfiguration may be suitable where the componentfunction is modified, inputs or outputs are added to specificcomponents, a component location is changed, and so forth. The systemmay then function in accordance with a wide range of protocols andsystem architectures. In the summary of FIG. 14, components arecyclically polled for data as indicated at step 238. As noted above,this polling is done by the monitoring station to acquire component andsystem operation parameters as well as component designation data. Atstep 240 the various views discussed above are built by the monitoringstation. The views may be built entirely from data accessed from thecomponents, but are preferably also built based upon informationaccessed from the database as indicated at step 242. By way of example,the database may be used for providing specific language textual labels,component configuration data, settings, and so forth. The views may alsoincorporate data accessed remotely as indicated at step 244. Suchremotely accessed data may include catalog information, drawings,trouble shooting information, or any other suitable data stored remotefrom the monitoring station and accessible via an appropriate networklink.

While the invention may be susceptible to various modifications andalternative forms, specific embodiments have been shown in the drawingsand have been described in detail herein by way of example only.However, it should be understood that the invention is not intended tobe limited to the particular forms disclosed. Rather, the invention isto cover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the followingappended claims.

1. A method for selling engineered electrical systems, the methodcomprising the steps of: generating a database for an electrical systemcomprising a plurality of programmable devices, the database includingdevice designation data; soliciting an order for the system; assemblingthe system including the plurality of programmable devices in accordancewith the order; coupling the assembled system to a network; andconfiguring memory objects within the devices by downloading, afterassembly of the system and via the network, at least the devicedesignation data from the database into respective memory objects of thedevices.
 2. The method of claim 1, comprising the further step ofdesigning the electrical system including the plurality of programmabledevices.
 3. The method of claim 1, wherein the device designation dataincludes data representative of a physical location of a device in thesystem.
 4. The method of claim 1, wherein the device designation dataincludes data representative of a function of a device in the system. 5.The method of claim 1, wherein the step of soliciting the order includescomputing price data based upon the database.
 6. The method of claim 1,comprising the further step of storing the database in a computercoupled to the system.
 7. The method of claim 1, wherein the systemincludes a plurality of subassemblies, at least a portion of thesubassemblies including at least one programmable device, and whereinthe memory objects of the programmable devices are configured afterarrangement of the devices in the subassemblies.
 8. The method of claim7, wherein the memory objects of the programmable devices are configuredprior to arrangement of the subassemblies in the system.
 9. The methodof claim 7, wherein the memory objects of the programmable devices areconfigured after arrangement of the subassemblies in the system.
 10. Themethod of claim 1, wherein the programmable devices include electricalpower switching devices mounted within an enclosure.
 11. The method ofclaim 10, wherein the system includes a motor control center.
 12. Amethod for coordinating sales and manufacturing of electrical systems,the method comprising the steps of: generating a system design databaseincluding data representative of programmable components and componentlayout for an electrical system; assembling the system components inaccordance with the component layout; coupling the assembled system to anetwork; and programming the programmable components by downloadinginformation from the database, after assembly of the system and via thenetwork, into respective memory objects of the programmable components.13. The method of claim 12, wherein the database includes datarepresentative of a physical location of each programmable component inthe system in accordance with the layout.
 14. The method of claim 12,wherein the step of programming the programmable components is performedfollowing final assembly of the components in the system.
 15. The methodof claim 12, wherein the step of assembling the system includes couplingthe programmable components to a data network in the system foraccessing data from each programmable component.
 16. A method forselling engineered electrical systems, the method comprising the stepsof: generating a database for an electrical system comprising aplurality of programmable devices, the database including devicedesignation data, the device designation data including datarepresentative of a physical location of a device in the system;assembling the system including the plurality of programmable devices;coupling the assembled system to a network; and configuring memoryobjects within the devices by downloading at least the devicedesignation data from the database, after assembly of the system and viathe network, into the memory objects.
 17. The method of claim 16,wherein the device designation data includes data representative of afunction of a device in the system.
 18. The method of claim 16,comprising the further step of storing the database in a computercoupled to the system.
 19. The method of claim 16, wherein the systemincludes a plurality of subassemblies, at least a portion of thesubassemblies including at least one programmable device, and whereinthe memory objects of the programmable devices are configured afterarrangement of the devices in the subassemblies.
 20. The method of claim19, wherein the memory objects of the programmable devices areconfigured prior to arrangement of the subassemblies in the system. 21.The method of claim 19, wherein the memory objects of the programmabledevices are configured after arrangement of the subassemblies in thesystem.
 22. The method of claim 19, comprising the further step ofdesigning the electrical system including the plurality of programmabledevices.
 23. A method for coordinating sales and manufacturing ofelectrical systems, the method comprising the steps of: generating asystem design database including data representative of programmablecomponents and component layout for an electrical system, theprogrammable components being programmed by downloading a portion of thedatabase into each programmable component; soliciting a sale of thesystem based upon the system design; assembling the system components inaccordance with the component layout; and programming the programmablecomponents by downloading at least device designation data from thedatabase, after assembly of the system and via a network, intorespective memory objects of each programmable component.
 24. The methodof claim 23, wherein the portion of the database includes datarepresentative of a physical location of each programmable component inthe system in accordance with the layout.
 25. The method of claim 23,wherein the step of programming the programmable components is performedfollowing final assembly of the components in the system.
 26. The methodof claim 23, wherein the step of assembling the system includes couplingthe programmable components to a data network in the system foraccessing data from each programmable component.
 27. A method forcoordinating sales and manufacturing of electrical systems, the methodcomprising the steps of: generating a system design database includingdata representative of programmable components and component layout foran electrical system, the programmable components being programmed bydownloading a portion of the database into each programmable component;assembling the system components in accordance with the componentlayout; coupling the assembled system to a network; and programming theprogrammable components by downloading at least the device designationdata from the database, after assembly of the system and via thenetwork, into respective memory objects of each programmable component.28. The method of claim 27, wherein the portion of the database includesdata representative of a physical location of each programmablecomponent in the system in accordance with the layout.
 29. The method ofclaim 27, wherein the step of programming the programmable components isperformed following final assembly of the components in the system. 30.The method of claim 27, wherein the step of assembling the systemincludes coupling the programmable components to a data network in thesystem for accessing data from each programmable component.